Engine sezied Please help!

[c&c]

Putting my engine back together. ( The engine will be dismantled again this winter for a complete rebuild and exterior vapor bast wash.)

What type of sealer/glue do you need for the case?
crankcase/cylinder gasket. Do I need to replace the 4 cylinder base o-rings?
All the bolts have heavy oxidation. I will tap/die all threads since aluminum is so fragile. Can I use some anti seize on the crank case threads.
I know some require internal screws need loktite.
Should I replace the crank shaft ignition seal? The one that is on it now does not want to be removed. I might have to pry it out.
How about upgrading the oil pump? Direct replacement I think.

What else should I look out for, any insider hints?

[Nessism]

I recommend a hard copy of the factory service manual. You can download it for free from Cliff's site and print it up or just purchase a hard copy. Read though all the particulars about the engine and commit it to memory. Details such as what sealers to use and what screws require loctite are all detailed there.

I'd caution against tapping out all the threads unless you get an undersize tap. You do not want to remove metal from the threads and taps often do that.

Only use OEM Suzuki gaskets and seals. Replace everything, including the valve stem seals. Gaskets are not cheap, but avoid going aftermarket if you value an oil tight fit.

Good luck

[c&c]

OK I will not tap unless I really have to, if the bolt is harder to turn then what is normal.
I still have to make sure they are clean and oxide free. I've learnt my lesson one and remember it quite well.
What do you do/use to deoxidize the inner threads? ( remove that white calcium like substance ).

[Nessism]

A fine bristle wire wheel on a bench grinder works well to clean the bolts. One of those undersize thread chasing taps for the female threads.

Threebond 1207B or 1194/1184 for the case halfs...http://www.amazon.com/Three-Bond-120.../dp/B008BYPRRI

[c&c]

Thank you for the info.

What size piston ring compressor do you use when putting back the cylinder barrel?
Do you need 4 or a minimum of 2?